WORK SITE 4S + DISCIPLINE (SHITSUKE

Definitions:
Seiri (Sifting) : Seggregate necessary/unnecessary material
Seiton (Sorting) : Define place for everything and everything in its place
Seiso (Cleaning) : Supercleaning - An activity to clean up dirt such as chips/g
Shiketsu (Spick and Span : Following above 3S (Seiri, Sifting, Seiso) neatly
Shitsuke (Discipline) : An activity to develop Human resource and focus towards a
CHECK AREA KEY Need improvement
Very bad (L-1)
1) Walk path /Gang way/Floor * No partition line & damaged Walk path /Gang way/Floor
Seiri (Sifting)

Seiton (Sorting) * Possibility of collision with veh. Movement

Passage

Seiso (Sweeping) * Dirt/oil on the floor.

2) Storage area or Stock Seiri (Sifting) * Unknown materials kept in storage area.
Storage area

area(Spare parts Stock/flow

racks/ Material Seiton (Sorting) * Product is kept w/o kanban.
/machine/tools/jigs)
Seiso (Sweeping) * Dirty storage area & kanban.

Seiri (Sifting) * Personal items are kept in area.

3) Work area/work Seiton (Sorting) * Fallen parts on the floor

table/line/pitch
Seiso (Sweeping) * No marking pitch to pitch (Home
position/standing position)
4) Production Seiri (Sifting) * Electrical/air hoses are messy & dirt on floor
equipment/Production area

Seiton (Sorting) * Equipment NDC/storage c/s not available.

* All lights, fan, equipment on condition during non- production

Seiso (Sweeping) time

5) Waste management in &

outside work area & truss Seiri (Sifting) * Waste segregation bin not available.
cleaning.
Seiton (Sorting) * Not segregated & disposed.
Production area

Seiso (Sweeping) * Dust on the roof & wall.

Seiri (Sifting) *Personal goods , unnecessary goods are messy.

Seiton (Sorting) * Documents are piled up messy.

7) Group Leader table
Seiso (Sweeping) * GL caps , desk are dirty.

Seiri (Sifting) * Documents & personal goods are kept on table.

Seiton (Sorting) * Tool , snacks etc are left out long time.
8) Rest area/, file rack & cup
board. * Tools, used PPE, news paper, snacks cover are left out from
long time.
Seiso (Sweeping)

9) Oil storage area Seiri (Sifting) * Stored together with non oil products.
(FIPG , Grease , Sealant ,
Adhesive , Spray Etc ) Seiton (Sorting) * Mixed types of oils are gathered randomly.
 9) Oil storage area
(FIPG , Grease , Sealant ,
Adhesive , Spray Etc )

Seiso (Sweeping) * Oil stain , foot steps are on the floor.

10) Display and Management Seiri (Sifting) * Old document left out & Document not updated.
Non-Production

sheet (Control board)

Seiton (Sorting) * Documents are overlapped & difficult to read.
area

* There is no relevant document visualization (NDC/ Sign

Seiso (Sweeping) boards/OCP/MSDS/CS) in place.
Discipline

11) Sustain member (TM

TMs

*Don’t know what is 4S .

knowledge)

12) Sustain supervisor

Discipline

* Supervisor not interested in 4S .

(TL/GL/SL)
Leader
 DISCIPLINE (SHITSUKE) ACTIVITY DIAGNOSIS SHEET
ry/unnecessary material
ything and everything in its place
ctivity to clean up dirt such as chips/grease/sand or floor
Seiri, Sifting, Seiso) neatly
p Human resource and focus towards achieving KPI results.
Need improvement
Bad(L-2)
* Partition line are messy/faded & damaged Walk path /Gang
way/Floor.
* No visualization to control collision with Veh.
Movement.
* Walk path/Gang way/Floor cleaning schedule is
there but not cleaned.
* Known material kept in mixed condition.
* Kanban is put but messy with product.
* Dust on products
* Unnecessary items are kept in work area.
* Fallen parts picked up but kept randomly.
* New pitch marking with old ones.
* Temporary alignment of wiring/ piping done.
* NDC/storage c/s available but not updated.
* Only process fan, lights and equipment's off during non-
production time.
* Waste segregation bin available w/o ISO std. color.
* Segregated but not disposed.
* One time roof & wall cleaned.
* Posting documents & control documents are not
spread.
* Documents are put in designated place
* Phones & PC are dirty.
* Documents are left out on the table.
* News paper , magazines etc left are temporarily.
* Designated location available for Tools, used PPE, news
paper, snacks cover with markings and visualization.
* Waste cloth , gloves are left out .
* Oils are gathered randomly inside compartment
line.
Bronze
Normal (L-3)
* New partition line with some old lines & patchwork done
* Visualization done for veh. movement.
* Walk path/Gang way/Floor cleaned on regular
basis
* Known material kept in separately.
* Kanban is put and products are in order.
* Products are protected from dust.
* Necessary goods are kept in work area.
* Fallen parts kept separately.
* Only required pitch lines available but peeled off.
* Proper Electrical/air wire/pipe routing is done.
* Updating NDC/storage c/s on daily basis
* All lights, fans & equipment's off condition during non-
production time
* Waste segregation bin are available with ISO std. color & kept
in designated location.
* On time segregation and disposal.
* Cleaning of roof & wall on frequent basis.
* No temporary rack for gloves etc.
* Documents on the table are arranged in order.
* Sweeping is done but little dirty.
* Work table is kept clean always.
8 Personal goods rack ( Pigeon rack ) is used for
personal goods.
* After break, rest area kept tidy but items not kept in
designated place.
* Stored only designated oil.
* Table & oil pan are maintained.
* Surrounding area of oil storage is dirty . 8 Waste cloths for cleaning split oil is prepared

* Documents doing visualized haphazard manner, * Only necessary documents are posted in place.
documents are about to fall.
* Expired documents are posted . * Different type of documents are mixed.

* Relevant documents visualization are (NDC/ Sign * Relevant documents visualization are (NDC/ Sign
boards/OCP/MSDS/CS/) messy. boards/OCP/MSDS/CS/) disturbed and can't
access/read.

*Don’t know the meaning of 4S well. * Member understand 4Sby general work safety rule card.

* 4S is implemented, but not decided when / who

* Supervisor just says to do 4S .
/ where. no system.
 Date :-

DIAGNOSIS SHEET Shop :-

PIC :-
Shop Manager :-

Passage
5

Sus 4
Sto
tain 3 ge area
ra
2
2
1

Sustain 1 Prod uction

a ea

Non-

Silver Gold Assess Assess Remarks

Good (L-4) Very Good(L-5) or 1 or 2
* New lines available, Old lines are erased & repaired the * Partitions lines are standardized & floor in good
damaged floor. condition. Take appropriate measure to prevent lines getting
damaged.
* Stop, look & go marking available * No chance of collision (Good condition)
* Have clear direction map.
* Daily clean and updated check sheet with rule. * Determined PIC for dirt/oil clean.

* Mark location for Known material.
* First-in First-out is implemented.
* Cleaning is done frequently & updated in c/s.
* Location for goods are marked & kept in order.
* Known material kept in designated location with
visualization.
* Kanban control and stock control is implemented
. Visualize min & max quantity.
* Have clear system for cleaning with designated
PIC & schedule .
* Goods are kept in designated area & put tidy.

* Marked/provided location to keep fallen parts * PIC available to manage fallen parts.
with visualization.
* Only required pitch lines available. * Pitch lines are well maintained.

* Frequently check electrical/air wiring/ piping. * No electric/air wiring/piping in man movement

area.
* For NDC/storage c/s abnormality findings action plan taken
* NDC/storage c/s updated & find abnormality. & standardize to prevent recurrence.

* All lights, fans & equipment's off condition & monitoring on * Displayed ON/OFF timing on the equipment & focus given to
daily basis improve Gentian.

* Waste segregation bin with ISO bin naming (Ex.

Plastic,Paper,Steel) & have monitoring system * Hoshin target of waste reduction are achieved.

* Confirm segregation and disposal on regular * PIC available to confirm segregation and disposal.
basis.
* Confirmation of periodic check available. * Determined person and added in regular c/s

* Only required goods are available. * Only required goods are placed in order.

* Titles / labels are ;put on documents / goods. * Easy to find / search any documents .

* Regular sweeping is done & maintain very clean. * Systemized regular cleaning .

* Documents are kept in designated location. * Files/Stands should be stored with proper
visualization & naming.
* Company goods & personal goods are segregated * All are fallowing rule of pigeon rack usage.
( Have a clear rule).

* All items are kept in designated location. * Periodically checking rest area condition by GL.

* Responsible person , amount , oil type are * Trying to reduce oil amount .
indicated.
* Oils are placed in order of oil types. * Necessary amount and types are controlled.
* Always cleaned up & kept tidy. * Measure is taken not to split oil.

* Posted documents are looking neat, clean & * Control board has proper layout marking &
periodically updated. naming.
* Posted as determined position. * Posted dead line is followed.

* Relevant document visualization (NDC/ Sign * Relevant document visualization (NDC/ Sign
boards/OCP/MSDS/CS/) in place & can boards/OCP/MSDS/CS/) done properly and
access/Read. determined PIC.

* All members can respond to 4S equations & 4S is

* Members point out 4S kaizen & implementing .
implemented.

* 4S is implemented systematically by map or rotation. Proper * Members are aware of 4S. So no need to receive directions
direction is given. to do.
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